System and method for assembling vehicle components with reinforced moldable rivet

ABSTRACT

A system for assembling vehicle components includes a die assembly securing first and second vehicle components having first and second apertures, respectively. The die assembly positions the first and second vehicle components with the first and second apertures overlapping, and at least one of the first and second vehicle components including a polymeric material. The system further includes a joining component extending through the first and second apertures. The die assembly supports the joining component, and the joining component including a support shank and a moldable body at least partially encasing the support shank. The system also includes a punch member selectively engaging and deforming the moldable body of the joining component. The die assembly guides the moldable body into engagement with the first and second vehicle components, and the die assembly locates the support shank within at least one of the first and second apertures.

BACKGROUND

Vehicles, such as automobiles, pick-up trucks, sport-utility vehicles, minivans, vans and other passenger vehicles, have traditionally utilized steel for their structure. However, the need for more efficient vehicles has led to consideration of a variety of structural and body materials, depending on particular vehicle design specifications. For example, to help meet fuel efficiency targets or requirements, e.g., Corporate Average Fuel Economy (CAFE) regulations, vehicles may incorporate non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics, in place of and/or in addition to traditional metallic components to reduce weight while maintaining suitable strength and stiffness performance. The integrity and robustness of the attachments of such components and materials impact the performance of the vehicle in a variety of ways, including the strength of the vehicle and the noise, vibration and harshness (NVH) characteristics of the vehicle. However, traditional manufacturing methods may not be applicable to alternative material needs. For example, reinforced composite materials cannot be welded, and they can cause metallic fasteners to corrode. Other joining techniques do not fit into mass-market cycle times. In another example, if the vehicle materials and the fasteners have significantly different thermal expansion properties, joint integrity may be compromised due to thermal cycling. As such, it is currently difficult to provide an attachment for non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics, sufficiently robust to be applied in mass market passenger vehicles.

DRAWINGS

FIG. 1 is a cross-sectional view of an exemplary assembly of vehicle components according to the principles of the present disclosure.

FIG. 2 is a cross-sectional view of exemplary vehicle structural members positioned with overlapping apertures therethrough, respectively.

FIGS. 3A-3C are cross-sectional views of exemplary fastening components for an assembly according to the principles of the present disclosure, the fastening components including a reinforced outer moldable body encasing a support body.

FIG. 4 is a cross-sectional view of another exemplary support body for an exemplary fastening component for an assembly according to the principles of the present disclosure.

FIGS. 5A-5C are cross-sectional views of system for forming an assembly according to the principles of the present disclosure.

FIG. 6 illustrates an exemplary process for forming an assembly according to the principles of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is an exemplary cross-sectional view of an exemplary assembly 10 of vehicle components according to the principles of the present disclosure. The exemplary assembly 10 includes first and second structural components 12 and 14. In one example, first and second components 12 and 14 are body components for a vehicle such as a passenger car, sport-utility vehicle, minivan, etc. In this exemplary implementation, the first and second components 12 and 14 abut each other. It should be understood that the principles of the present disclosure may be applicable to a variety of vehicle assemblies, including an assembly with more than two components.

According to the principles of the present disclosure, at least one of the first and second components 12 and 14 are formed from and/or include non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics. In one example, one of the first and second components 12 and 14 may be formed of a carbon fiber reinforced plastic material, and the other may also be formed of a carbon fiber reinforced plastic material, another non-metallic, plastic, composite and/or reinforced material, or a metallic material. The first and second components 12 and 14 may have substantially identical material compositions.

With further reference to FIG. 2, the first and second components 12 and 14 include first and second apertures 16 and 18, respectively. First and second components 12 and 14 are positioned with the first and second apertures 16 and 18 overlapping each other. In some implementations, as shown in the exemplary illustration of FIG. 2, the first and second components 12 and 14 may be posited to center, i.e., concentrically align, the first and second apertures 16 and 18.

The assembly 10 further includes a fastener or joining component 20 extending through the first and second apertures 16 and 18 of the first and second components 12 and 14. The joining component 20 includes a moldable outer body 22 at least partially encasing a relatively rigid support shank or body 24. It should be understood that the description herein of the outer body “at least partially encasing” the support body includes, in some implementations, where a portion or portions of a support body or shank, or feature thereof, may protrude through the outer body to the exterior surface of the joining component, but the outer body extends sufficiently around the support body to maintain the support body fixed relative to the outer body. Furthermore, as used herein, “moldable” refers to both materials that may, under certain conditions, be repeatedly deformed and melted, e.g., thermoplastic polymer materials, and materials, e.g., thermosetting polymer materials, that may substantially irreversibly cure or otherwise chemically change due to applied deformation conditions i.e., heat, pressure, etc. Accordingly, the outer body 22 may include one of a thermoplastic material, e.g., nylon, and a thermoset material, e.g., epoxy or polyester. In addition to such a moldable material, the outer body 22 may include a reinforcement material 32.

With further reference to FIGS. 3A-C, additional joining components 20′ and 20″, along with the joining component 20, are all illustrated in an exemplary pre-deformed state, e.g., in a substantially cylindrical shape. The additional joining components 20′ and 20″ have outer bodies 22′ and 22″, respectively, which include varying reinforcement materials 32′ and 32″, respectively. For example, the reinforcement materials 32, 32′ and 32″ may include one or more of a variety of fibrous and/or particulate materials, e.g., carbon, glass, aramid and other natural fibers; talc and metallic flakes; and glass beads. It should be understood that, apart from the variation in reinforcement materials, the description herein of joining component 20 equally applies to joining components 20′ and 20″.

As illustrated in FIGS. 1 and 3A-C, support bodies 24, 24′ and 24″ are respectively at least partially encased by the moldable outer bodies 22, 22′ and 22″ and each may have a substantially cylindrical shape. Referring to FIG. 4, another support body 24′″ includes ribbed locking members 34′″ protruding from the radially outer surface thereof. The locking members 34′″ help mechanically fix the support body 24′″ relative to the moldable outer body of the respective joining component in a vehicle component assembly according to the principles of the present disclosure. For example, the locking members 34′″ would provide additional resistance to lengthwise movement of the support body 24′″ relative to an at least partially encasing outer body. It should be understood that a support body or shank according to the principles of the present disclosure may include many geometries, including protruding locking members in a variety of configurations, such as a spaced apart knobs or a thread. Such features may significantly affect the cross sectional area of the support body or shank. It should also be understood that, apart from inclusion of locking members in the support body 24′″, the description herein of the support bodies 24, 24′, 24″ and 24′″ are equally applicable to each other.

The system and a process 100 for forming the assembly 10 with the first and second components 12 and 14 and the joining component 20 is illustrated in FIGS. 5A-C and 6. With particular reference to FIG. 5A and a block 102 of FIG. 6, a die assembly 50 secures the first and second components 12 and 14, with the first and second apertures 16 and 18 overlapping, with a base component 52 and a nose component 54. The base component 52 has a molding recess 56, and the nose component 54 has a through aperture 58 overlapping with the molding recess 56. The first and second components 12 and 14 are positioned in the die assembly 50 with the first and second apertures 16 and 18 overlapping with the molding recess 56 and the through aperture 58. As illustrated in FIGS. 5A-C, the first and second apertures 16 and 18 may be centered, i.e., concentrically aligned, with the molding recess 56 and the through aperture 58.

Referring in particular to FIG. 5B and a block 104 of FIG. 6, with the first and second components 12 and 14 secured in the die assembly 50, the joining component 20 may be extended through the through aperture 58 of the nose component 54 and the first and second apertures 16 and 18 and into engagement with the molding recess 56. In the exemplary illustrated implementation, the joining component 20 is positioned through the first and second components 12 and 14 in a substantially cylindrical, pre-deformed configuration.

Referring in particular to FIG. 5C and a block 106 of FIG. 6, with the joining component 20 positioned between the first and second vehicle components 12 and 14, a punch member 60 of the die assembly 50 extends into the through aperture 58 of the nose component 54 and engages the joining component 20, as illustrated in FIG. 5C. The punch member 60 deforms the moldable outer body 22 of the joining component 20 into the molding recess 56, the first and second apertures 16 and 18, and the region of the through aperture 58 between the punch 60 and the first vehicle component 12.

As illustrated in FIGS. 5A-C, a temperature control apparatus 62 may be thermally coupled to the die assembly 50 to provide heating or cooling to aid the curing and/or the deformation process of the moldable outer body 22. For example, referring to a block 108 of FIG. 6, one portion of the process 100 may be determining whether such temperature control is needed or desired. If not, referring to a block 110 of FIG. 6, the outer body 22 of the joining component 20 is deformed through force applied by the punch member 60 primarily, e.g., when the moldable material of the outer body 22 is a thermoplastic material.

Referring again to the block 108 of FIG. 6, if temperature control of the die assembly 50 is needed or desired, e.g., the moldable material of the outer body 22 is in the form of a thermosetting material and heat is required to cure the outer body 22, or heat facilitates deformation thereof. For example, the temperature control apparatus 62 may include a heater in thermodynamic communication with the die assembly 50 to operate as required for the particular materials and operating conditions. In another example, to facilitate manufacturing, e.g., by speeding up the process 100, the temperature control apparatus 62 may also have a cooler in thermodynamic communication with the die assembly 50 to speed the curing or hardening of the moldable outer body 22 in the deformed shape. Accordingly, referring to a block 112 of FIG. 6, the temperature control apparatus 62 is operated as desired or needed, and the process 100 continues to the block 110, where deformation through force and/or temperature control occurs.

As deformed by the punch member 60 according to the principles of the present disclosure, the joining component 20 includes first and second flanges 72 and 74 of the outer body 22 clamping the first and second components 12 and 14 together. In this exemplary illustrated implementation, the first flange 72 directly engages an outer surface 82 of the first component 12, and the second flange 74 directly engages an outer surface 84 of the second component 14. In some implementations, e.g., where the moldable material of the outer body 22 is a thermosetting material, one or both of the first flange 72 and the second flange 74 may adhesively bond to the first and second vehicle components 12 and 14, respectively. In such an implementation, the first flange 72 may have a bond 86 with the outer surface 82 of the first component 12, and the second flange 74 may have a bond 88 with the outer surface 84 of the second component 14.

In the deformation of the moldable outer body 22, the support body 24 is positioned to extending into the first and second apertures 16 and 18. In other implementations, the support body or shank 24 may extend into only one of the first and second apertures 16 and 18.

As shown in the exemplary illustrations, the first and second apertures 16 and 18 may be substantially centered relative to each other, and the deformed joining component 20 and the support body 24 thereof may be substantially centered relative to the first and second apertures 16 and 18. In other implementations, the deformed joining component 20 and the support body 24 thereof may be substantially centered relative to at least one of the first and second apertures 16 and 18.

In the drawings, the same reference numbers indicate the same elements. Further, some or all of these elements could be changed. Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It should be understood that, as used herein, exemplary refers to serving as an illustration or specimen, illustrative, or typical. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.

All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. 

The invention claimed is:
 1. A method for assembling vehicle components, the method comprising: overlapping first and second apertures of first and second vehicle components, respectively, at least one of the first and second vehicle components including a polymeric material; extending a joining component through the first and second apertures, the joining component including a support shank completely encased by a moldable body, the support shank including at least one locking member protruding radially into the moldable body; positioning the support shank within at least one of the first and second apertures; and deforming the moldable body into engagement with the first and second vehicle components, wherein deforming the moldable body includes mechanically deforming the moldable body with a punch member.
 2. The method of claim 1, wherein deforming the moldable body includes heating the moldable body.
 3. The method of claim 2, further comprising cooling the deformed moldable body.
 4. The method of claim 2, further comprising cooling the deformed moldable body with a cooler in thermodynamic communication with a die assembly securing the first and second vehicle components.
 5. The method of claim 1, further comprising adhesively bonding the moldable body to at least one of the first and second vehicle components.
 6. The method of claim 5, further comprising adhesively bonding the moldable body to both of the first and second vehicle components.
 7. The method of claim 1, wherein the joining component is centered relative to at least one of the first and second apertures.
 8. The method of claim 7, wherein the support shank is centered relative to the at least one of the first and second apertures within which the support shank is positioned.
 9. The method of claim 1, further comprising aligning the first and second apertures.
 10. The method of claim 1, further comprising directly abutting the first and second vehicle components.
 11. The method of claim 1, further comprising securing the first and second vehicle components between a base component and a nose component of a die assembly, wherein the base component includes a molding recess, the nose component includes a through aperture, and the first and second vehicle components are secured so that the first and second apertures overlap with the molding recess and the through aperture.
 12. The method of claim 11, wherein mechanically deforming the moldable body with a punch member includes extending the punch member into the through aperture to engage the moldable body. 